Multiple panel airbag and method

ABSTRACT

An airbag cushion for use in a vehicle restraint system is provided. The airbag cushion is formed from a notched body panel and a rectilinear center panel by a series of substantially straight seams which reduces substantially the elongation of the air bag cushion upon impact on collision of the vehicle in which it is installed. A method of forming the cushion according to the present invention is also provided.

REFERENCE TO RELATED APPLICATION

This application claims priority to and benefit of U.S. ProvisionalPatent Application Serial No. 60/241,171, filed Oct. 17, 2000, herebyincorporated by reference herein.

This application is related to U.S. patent application Ser. No.09/640,682, filed Aug. 18, 2000, entitled “Multiple Panel Airbag andMethod”, and is hereby incorporated by reference.

This application is related to commonly owned, U.S. Pat. No. 6,019,390,issued Feb. 1, 2000, hereby incorporated by reference.

FIELD OF THE INVENTION

The present invention relates to inflatable protective cushions, andprovides a cushion construction particularly useful in the frontal orside protection of occupants in a transportation vehicle, such as anautomotive vehicle, railroad, car, airplane or the like. The inventionis also directed to a module and/or overall vehicle restraint systemincluding the inventive airbag cushion. A process or method for formingthe cushion according to the present invention is also provided.

BACKGROUND

As described in U.S. Pat. No. 6,019,390, inflatable protective cushionsused in passenger vehicles are a component of relatively complex passiverestraint systems. The main elements of these systems are: an impactsensing system, an ignition system, a propellant material, an attachmentdevice, a system enclosure, and an inflatable protective cushion. Uponsensing an impact, the propellant is ignited causing an explosiverelease of gases filling the cushion to a deployed state which canabsorb the impact of the forward movement of a body and dissipate itsenergy by means of rapid venting of the gas. The entire sequence ofevents occurs within about 30 milliseconds. In the un-deployed state,the cushion is stored in or near the steering column, the dashboard, ina door, or in the back of a front seat placing the cushion in closeproximity to the person or object it is to protect.

Inflatable cushion systems commonly referred to as air bag systems havebeen used in the past to protect both the operator of the vehicle andpassengers. Systems for the protection of the vehicle operator havetypically been mounted in the steering column of the vehicle and haveutilized cushion constructions directly deployable towards the driver.These driver-side cushions are typically of a relatively simpleconfiguration in that they function over a fairly small well-definedarea between the driver and the steering column. One such configurationis disclosed in U.S. Pat. No. 5,533,755 to Nelsen et al., issued Jul. 9,1996, the teachings of which are incorporated herein by reference.

Inflatable cushions for use in the protection of passengers againstfrontal or side impacts must generally have a more complex configurationsince the position of a vehicle passenger may not be well defined andgreater distance may exist between the passenger and the surface of thevehicle against which that passenger might be thrown in the event of acollision. Prior cushions for use in such environments are disclosed inU.S. Pat. No. 5,520,414 to Bishop, issued May 28, 1996; U.S. Pat. No.5,454,594 to Krickl issued Oct. 3, 1995; U.S. Pat. No. 5,423,273 toHawthorn et al. issued Jun. 13, 1995; U.S. Pat. No. 5,316,337 to Yamajiet al. issued May 31, 1994; U.S. Pat. No. 5,310,216 to Wehner et al.issued May 10, 1994; U.S. Pat. No. 5,090,729 to Watanabe issued Feb. 25,1992; U.S. Pat. No. 5,087,071 to Wallner et al. issued Feb. 11, 1992;U.S. Pat. No. 4,944,529 to Backhaus issued Jul. 31, 1990; and U.S. Pat.No. 3,792,873 to Buchner et al. issued Feb. 19, 1974, all of which areincorporated herein by reference.

The majority of commercially used restraint cushions are formed of wovenfabric materials utilizing multifilament synthetic yarns of materialssuch as polyester, nylon 6 or nylon 6,6 polymers. Representative fabricsfor such use are disclosed in U.S. Pat. No. 4,921,735 to Bloch issuedMay 1, 1990; U.S. Pat. No. 5,093,163 to Krummheuer et al. issued Mar. 3,1992; U.S. Pat. No. 5,110,666 to Menzel et al. issued May 5, 1992; U.S.Pat. No. 5,236,775 to Swoboda et al. issued Aug. 17, 1993; U.S. Pat. No.5,277,230 to Sollars, Jr. issued Jan. 11, 1994; U.S. Pat. No. 5,356,680to Krummheuer et al. issued Oct. 18, 1994; U.S. Pat. No. 5,477,890 toKrummheuer et al. issued Dec. 26, 1995; U.S. Pat. No. 5,508,073 toKrummheuer et al. issued Apr. 16, 1996; U.S. Pat. No. 5,503,197 to Boweret al. issued Apr. 2, 1996, and U.S. Pat. No. 5,704,402 to Bowen et al.issued Jan. 6, 1998, all of which are incorporated herein by reference.

As will be appreciated, the permeability of the cushion structure is animportant factor in determining the rate of inflation and subsequentrapid deflation following the impact event. In order to control theoverall permeability of the cushion, it may be desirable to usediffering materials in different regions of the cushion. Thus, the useof several fabric panels in construction of the cushion may prove to bea useful design feature. The use of multiple fabric panels in thecushion structure also permits the development of relatively complexthree dimensional geometries which may be of benefit in the formation ofcushions for passenger side applications wherein a full bodied cushionis desired. While the use of multiple fabric panels provides severaladvantages in terms of permeability manipulation and geometric design,the use of multiple fabric panels for use in passenger side restraintcushions has historically required the assembly of panels havingmultiple different geometries involving multiple curved seams.

As will be appreciated, an important consideration in cutting panelstructures from a base material is the ability to maximize the number ofpanels which can be cut from a fixed area through close-packed nestingof the panels. It has been found that minimizing the number of differentgeometries making up panels in the cushion and using geometries withsubstantially straight line perimeter configurations generally permitsan enhanced number of panels to be cut from the base material. The useof panels having generally straight line profiles has the added benefitof permitting the panels to be attached to one another usingsubstantially straight seams or be substantially formed during theweaving process using a jacquard or dobby loom.

SUMMARY OF THE INVENTION

The present invention provides a passenger side airbag configurationwhich may be constructed from two body panel sections and one centerpanel section. Each section may be made up of more than one panel orpiece. The body panel sections are connected to one another and to thecenter panel by a series of substantially flat, straight seams. Thus,the airbag configuration formed according to the present inventionresults in highly efficient utilization of materials and may beconstructed substantially without the need for complex curved seamingoperations. As such, the present invention constitutes a usefuladvancement over the present art.

In view of the foregoing, it is a general object of the presentinvention to provide a highly effective easily manufactured inflatableoccupant restraining cushion.

It is a more particular object of the present invention to provide aninflatable occupant restraining cushion manufactured from two body panelsections and a center panel or section. Each panel section may be madeup of more than one panel or piece.

It is a further object of the present invention to provide an inflatableoccupant restraining cushion manufactured from panel sections and/orpanels connected to one another by a series of substantially straight,flat seams.

It is another object of the present invention to provide an inflatableoccupant restraining cushion manufactured from the fabric panel sectionswoven and connected together on a jacquard or dobby weaving machine suchthat a substantially complete cushion is formed on the weaving machine.

It is yet an additional object of the present invention to provide aninflatable occupant restraining cushion formed from panel sectionshaving two basic geometries which can be nested in close spaced relationacross a sheet of material thereby promoting good material utilizationin a cut and sew operation.

A further object of the invention is to provide an inflatable occupantrestraining cushion which employees a body panel section so designed toprovide an air bag portion formed with straight seams which inhibitsextreme expansion of the restraining cushion upon release of gas thereindue to detonation of the inflator upon impact caused by a collision ofthe automobile or truck in which it is mounted.

It is still a further object of the present invention to provide aneasily manufactured inflatable occupant restraining cushion formed frommaterial panels which exhibit differing air permeability characteristicsso as to optimize the overall air permeability characteristics of thecushion.

It is yet an additional object of the present invention to provide aneasily manufactured inflatable occupant restraining cushion formed froma combination of coated and uncoated material panels.

Another object of the invention is to provide a method of making a lowcost inflatable protective cushion of simple and structurally efficientdesign.

To achieve these and other objects and in accordance with the purpose ofthe invention, as embodied and broadly described herein, the presentinvention provides an airbag cushion for use in a vehicle restraintsystem, which in the most preferred embodiment includes two body panelsections of substantially similar geometry joined to one another by twosubstantially straight seams along corresponding lateral boundary edges.The boundary segments of the body panels which are not joined to oneanother are joined around the perimeter of a quadrilateral center panelby a series of substantially straight seams thereby forming aninflatable cushion structure.

Additional objects and advantages of the invention will be set forth inpart in the description which follows, and in part will be obvious fromthe description, or may be learned by practice of the invention. It isto be understood that both the foregoing general description and thefollowing detailed description of preferred embodiments are exemplaryand explanatory only, and are not to be viewed as in any way restrictingthe scope of the invention as set forth in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate several potentially preferredembodiments of the invention and together with the description serve toexplain the principles of the invention wherein:

FIG. 1 illustrates a cutaway view of the inflatable cushion of thepresent invention in deployment between a passenger and a dash panel;

FIG. 2 is a front perspective view of the cushion according to thepresent invention with its seams on the exterior wherein the term“front” is meant to designate that portion of the cushion which isintended to be impacted by a person or object to be protected;

FIGS. 3A-3C illustrate the body panel sections and center panel of afirst potentially preferred embodiment of the cushion according to thepresent invention;

FIGS. 4A-4C illustrate the body panel sections and center panel of asecond potentially preferred embodiment of the cushion according to thepresent invention for use in an environment where an expended curvedprofile is desirable to meet depth requirements;

FIGS. 5A-5C illustrate the body panel sections and center panel of athird potentially preferred embodiment of the cushion according to thepresent invention for use in covering substantial elongated areas as maybe desired in full body or side impact applications;

FIGS. 6A-6C illustrate the body panel sections and center panel of yet afourth potentially preferred embodiment of the cushion according to thepresent invention which provides for an expanded frontal surface forimpact by a person or occupant to be protected;

FIG. 6D illustrates the front view of the center panel and body panelsections of FIGS. 6A-6C with the panels joined together;

FIGS. 7A-7C illustrates various potentially preferred mouthconfigurations for use in the cushion according to the presentinvention;

FIG. 8 is a front perspective view of the cushion according to anotherembodiment of the present invention with its seams on the exteriorwherein the term “front” is meant to designate that portion of thecushion which is intended to be impacted by a person or object to beprotected;

FIGS. 9A-9C illustrate the body panel sections and center panel ofanother potentially preferred embodiment of the cushion according to thepresent invention and FIG. 8;

FIGS. 10-10C illustrate the body panel section panels and center panelof yet another potentially preferred embodiment of the cushion accordingto the present invention for use in an environment where an expandedcurved profile is desirable to meet depth requirements;

FIGS. 11A-11C illustrate the body panel section panels and center panelof still another potentially preferred embodiment of the cushionaccording to the present invention for use in covering substantialelongated areas as may be desired in full body or side impactapplications;

FIGS. 12A-12C illustrate the body panel section panels and center panelof another potentially preferred embodiment of the cushion according tothe present invention which provides for an expanded frontal surface forimpact by a person or occupant to be protected;

FIG. 12D illustrates the front view of the center panel and body panelsection panels of FIGS. 12A-12C with the panels joined together;

FIGS. 13A-13C illustrate various potentially preferred mouthconfigurations for use in the cushion according to the presentinvention;

FIGS. 14A-14C illustrate the top, center (body), and bottom panelsections of another embodiment according to the present invention;

FIGS. 15A-15C illustrate the top, center (body), and bottom panelsections of yet another embodiment according to the present invention;

FIGS. 16A-16C illustrate the top, center (body), and bottom panelsection panels of FIGS. 14A-14C in accordance with another embodiment;

FIGS. 17A-17C illustrate the top, center (body), and bottom panelsection panels of FIGS. 15A-15C according to another embodiment of thepresent invention;

FIGS. 18A-18D represent the respective panel sections of anotherembodiment of the present invention with a loop pocket to hold aninflator;

FIGS. 19A-19D illustrate the panel section panels of FIGS. 18A-18Daccording to yet another embodiment of the present invention;

FIG. 20 is a schematic view of a notched body panel in accordance withanother embodiment of the present invention;

FIG. 21 is a schematic view of a notched body panel in accordance withanother embodiment of the present invention;

FIG. 22 is a schematic view of a center (or front) panel for use withthe body panel of FIG. 21;

FIG. 23 is a schematic side view representation of an inflated airbaghaving the front and rear panels shown in FIGS. 21 and 22 with thenotches sewn shut to provide the desired profile or depth;

FIG. 24 is a schematic view of a notched body panel in accordance withstill another embodiment of the present invention; and,

FIG. 25 is a schematic view of a center (or front) panel adapted to beused with the body panel of FIG. 24.

DESCRIPTION OF PREFERRED EMBODIMENTS

Reference will now be made in detail to potentially preferredembodiments of the invention, examples of which have been illustrated inthe accompanying drawings. It is to be understood that it is in no wayintended to limit the invention to such illustrated and describedembodiments. On the contrary, it is intended to cover all alternatives,modifications and equivalents as may be included within the true spiritand scope of the invention as defined by the appended claims andequivalents thereto.

Turning now to the drawings, wherein like elements are denoted by likereference numerals throughout the various views, in FIG. 1 there isshown an inflatable restraint cushion 10 for use with an inflator 12 toprotect a vehicle occupant 14 from impacting against a dash panel 16,windshield 18 or other interior surface in the event of a collision. Aswill be noted, the inflatable restraint cushion 10 includes a frontalimpact center panel or section 20 and two body panel sections 22, 24which are connected to and extend away from the frontal impact centerpanel to establish fluid communication with the inflator 12.

In FIG. 2, there is illustrated a potentially preferred seamingarrangement for use in establishing the connective relationship betweenthe frontal impact center panel 20 and the body panel sections 22, 24.As illustrated, the body panel sections 22, 24 are connected to oneanother by means of a substantially straight body seam 26. While onlyone such body seam 26 is illustrated in FIG. 2 it is to be understoodthat in the preferred embodiment an identical seam is likewise disposedalong the length of the body panel sections 22, 24 on the opposite sideof the restraint cushion 10. In the illustrated and potentiallypreferred embodiment as shown in FIG. 2, the frontal impact panel 20 ispreferably joined to the non-seamed edges of the body panel sections 22,24 by means of a series of substantially straight face seams 27 asshown. Once the seaming operations are completed, the inflatablerestraint cushion 10 is preferably turned inside out so as to place theseams on the interior thereof during an inflation event. Moreover, whilethe assembly configuration as shown in FIG. 2 has a relatively straightline box-like configuration, once the cushion 10 is turned inside outand inflated, the profile tends to assume the generally desirablerounded profile as illustrated in FIG. 1.

It will be understood that reference herein to seams or seamingoperations include not only traditional sewn seams but also by way ofexample only and not limitation, interwoven seams, adhesive seams, meltbonded seams, ultrasonic seams, and other suitable attachment methods asmay be known to those of skill in the art. Thus, while traditional sewnseams may be preferred, the invention is in no way limited thereto.

In FIGS. 3A-3C there is illustrated a first potentially preferredconfiguration for the body panel sections 22, 24 and the frontal impactcenter panel or section 20 of the inflatable restraint cushion 10according to the present invention. As illustrated, each of the bodypanel sections 22, 24 is generally of a diamond shape including asubstantially straight upper boundary edge 28, 30 bounded by a firstterminal end “A” and a second terminal end “B”. Each of the body panelsections 22, 24 also preferably includes a first substantially straightlateral boundary edge 34, 38 and a second substantially straight lateralboundary edge 36, 40. Each of the body panel sections 22, 24 alsopreferably includes a first substantially straight intermediate boundaryedge 42, 44 extending between the first terminal end of the upperboundary edge 28, 30 and the first lateral boundary edge 34, 38 asshown. A second substantially straight intermediate boundary edge 46, 48preferably connects the second terminal end of the upper boundary edge28, 30 of each body panel section to the second lateral boundary edge36, 40 thereof.

As illustrated in FIG. 3C the frontal impact center panel 20 ispreferably of a rectilinear geometry including four substantiallystraight boundary edges 52, 54, 56, and 58 as shown. The impact centerpanel 20 is preferably of a square or rectangular geometry havingsubstantially right angles between intersecting boundary edges. It iscontemplated that a non-square elongate geometry having a lengthdimension which is substantially greater than the width dimension may beutilized. In such a geometry the length dimension would preferably be atleast ten percent greater that the width dimension, would morepreferably be at least 20 percent greater than the width dimension, andwould most preferably be at least 30 percent greater than the widthdimension, although it is to be understood that such length dimensionmay be substantially greater than these identifiable minimums and may,in fact be many times the width dimension if a substantial area is to becovered.

The materials of construction from which the frontal impact center panel20 and each body panel section 22, 24 are formed, may be either similaror dissimilar from one another. Each of these panels may be formed froma number of materials including by way of example only and notlimitation woven fabrics, knitted fabrics, non-woven fabrics, films andcombinations thereof. Woven fabrics may be preferred with woven fabricsformed of tightly woven construction such as plain or panama weaveconstructions being particularly preferred. Such woven fabrics may beformed from yarns of polyester, polyamides such as nylon 6 and nylon-6,6or other suitable material as may be known to those in the skill in theart. Multifilament yarns having a relatively low denier per filamentrating of not greater than about 1-4 denier per filament may bedesirable for bags requiring particular good foldability.

In instances where the cushion is to be formed by sewing together precutpanel sections 20, 22, 24 from a base material and a woven fabric isutilized for a frontal impact center panel 20 such panel is preferablycut from the fabric such that its boundary edges are disposedsubstantially parallel to the warp and fill directions. Likewise, ininstances where woven fabric is utilized to form the body panel sections22, 24 such panels are preferably cut such that the upper boundary edges28, 30 run substantially parallel to either the warp or the filldirections.

In application, woven fabrics formed from synthetic yarns having lineardensities of about 40 denier to about 1200 denier are believed to beuseful in the formation of the cushion 10 according to the presentinvention. Fabrics formed from yarns having linear densities of about315 denier to about 840 denier are believed to be particularly useful,and fabrics formed from yarns having linear densities in the range ofabout 400 denier to about 650 denier are believed to be most useful.

While each of the panels 20, 22, 24 may be formed of the same material,the panels may also be formed from differing materials and orconstructions. By way of example only and not limitation, one or both ofthe body panel sections 22, 24 may be formed from an uncoated relativelyhigh permeability fabric having an air permeability of about 5 CFM persquare foot or higher while the center panel 20 is formed from a coatedor uncoated fabric having an air permeability of about 3 CFM per squarefoot or less when measured at a differential pressure of 0.5 inches ofwater across the fabric. Fabrics having permeabilities of about 1-3 CFMper square foot may be desirable in either the body panels or centerpanel section. Fabrics having permeabilities below 2 CFM and preferablybelow 1 CFM in the uncoated state may be preferred. Such fabrics whichhave permeabilities below 2 CFM which permeability does notsubstantially increase by more than a factor of about 2 when the fabricis subjected to biaxial stresses in the range of up to about 100 poundsforce may be particularly preferred. Fabrics which exhibit suchcharacteristics which are formed by means of fluid jet weaving may bemost preferred.

In the event that a coating is utilized on one or more material panels,neoprene, silicone, urethanes, or polyamides may be preferred. Coatingssuch as disperse polyamides having dry add on weights of about 0.6ounces per square yard or less and more preferably about 0.4 ounces persquare yard or less and most preferably about 0.3 ounces per square yardor less may be particularly preferred so as to minimize fabric weightand enhance foldability. It is, of course, to be understood that asidefrom the use of coatings, different characteristics in various panelsmay also be achieved through the use of fabrics incorporating differingweave densities and/or finishing treatments such as calendaring as maybe known to those in the skill of the art.

While the restraint cushion 10 according to the present invention hasbeen illustrated and is described herein in terms of the principal panelsections 20, 22, 24, it is to be understood that such cushion 10 mayalso include additional components such as shape defining tethers, gasvents, mouth reinforcements, and the like as may be known to those inthe skill of the art.

The assembly and construction of the cushion 10 according to the presentinvention is best understood through reference to FIG. 2 and FIGS.3A-3C. In the preferred practice of the present invention, substantiallystraight body seams 26 are applied along corresponding lateral boundaryedges 34, 38 and 36, 40. The frontal impact center panel 20 is seamedalong two opposing boundary edges 52, 54 to the substantially straightupper boundary edges 28, 30 of the body panel sections 22, 24. Theintermediate boundary edges 42, 44, 46, 48 are seamed along theremaining boundary edges 56, 58 of the center panel 20 so as to form anenclosed structure.

In the illustrated and potentially preferred embodiment, the totalperimeter length of the center panel 20 is substantially equal to thecombined lengths of the upper boundary edges 28, 30 and intermediateboundary edges 42, 44, 46, 48 of the body panel sections. The use ofsuch corresponding length segments permits complete closure usingsubstantially straight seams without the occurrence of substantialpuckering which may result from excess material. In the most preferredembodiment, the upper and lower boundary edges 52, 54 of the centerpanel will be of substantially equal length to the upper boundary edges28, 30 of the body panel sections while the first substantially straightintermediate boundary edges 42, 44 of the body panel sections have acombined length which is substantially equal to the length of the firstlateral boundary edge 56 of the center panel with the combined lengthsof the second substantially straight intermediate boundary edges 46, 48of the body panel sections being substantially equivalent to the lengthof the second center panel lateral boundary edge 58.

As will be appreciated, the preferred geometry permits formation of anenclosed cushion by means of a series of flat, straight seamingoperations to form the body seams 26 and face seams 27 as illustrated inFIG. 2. Such flat, straight seaming operations greatly enhance theefficiency of the manufacturing process. In addition, in the event thata woven fabric is chosen as the material of construction, each of theface seams 27 will fall along the primary yarn directions in the centerpanel 20 thereby lending added stability to the frontal impact area ofthe cushion.

In FIGS. 4A-4C there is illustrated a frontal impact center panel orsection 120 and corresponding body panel sections 122, 124 for use information of a cushion which has a deep arcuate expanded profile such asmay be desirable for surrounding a dash panel in a top mountconfiguration. That is, where the cushion is deployed from the top ofthe dash panel rather than from a position directly opposing theoccupant. As will be appreciated, the construction and assembly of therestraint cushion incorporating the panel sections as illustrated inFIGS. 4A-4C is substantially identical to the description provided abovein relation to FIGS. 3A-3C. However, as illustrated the mouth-formingopening is arranged so as to accommodate an inflator in a top mountconfiguration. Panel sections 120, 122, and 124 have boundary edges 152,154, 156, 158; 128, 134, 136, 142, 146; and, 130, 138, 140, 144, 148,respectively.

In FIGS. 5A-5C there is illustrated a frontal impact center panel orsection 220 and corresponding body panel sections 222, 224 useful inapplications requiring a cushion having an elongated profile. By way ofexample and not limitation, such application may include full frontalimpact protection or side impact protection for an occupant's head andtorso. As illustrated, in this embodiment the body panel sections 222,224 are characterized by upper boundary edges 228, 230 of substantiallength and a center panel 220 has corresponding substantial lengthdimensions along its upper and lower boundary edges 252, 254. As will benoted, this length dimension is more than two times the width asmeasured along the lateral boundary edges 256, 258. Once again, theconstruction is substantially similar to that described in relation tothe prior configurations such that corresponding first lateral boundaryedges 234, 238 are joined together; corresponding second lateralboundary edges 236, 240 are joined together upper and lower center panelboundary edges 252, 254 are joined to the upper boundary edges 228, 230of the body panel sections; first intermediate boundary edges 242, 244of the body panel sections are joined along a first lateral boundaryedge 256 of the center panel and intermediate boundary edges 246, 248 ofthe body panel sections are joined along the remaining lateral boundaryedge 258 of the center panel 220.

As will be appreciated, the resultant elongated cushion structure may bedivided into individual lobes or chambers through the application ofinflation limiting seams or tethers. As will be appreciated theincorporation of such lobes may be desirable to protect differentsections of the body which behave in differing manners during an impactevent. By way of example only and not limitation, an upper lobe may beused to protect the head and torso while a lower lobe may be used toprotect the knee. One potentially preferred seaming configuration todevelop such lobes is disclosed in my pending application Ser. No.08/969,823 the contents of which are incorporated herein by reference.

In FIGS. 6A-6D there is illustrated yet another embodiment of thepresent invention which includes a rectilinear center panel or section320 and two body panel sections 322, 324. As illustrated, the body panelsections of this embodiment are characterized by a relatively long,substantially straight upper boundary edge 328, 330 and intermediateboundary edges 342, 344, 346, 348 which are disposed at substantiallyright angles to such upper boundary edges. Panel section 320 hasboundary edges 352, 354, 356, and 358.

The cushion assembly of this embodiment differs slightly from that ofprevious embodiments in that the body panel sections 322, 324 are seamedtogether along the corresponding lateral boundary edges 334, 338 and336, 340 as well as along corresponding intermediate boundary edges 342,344 and 346, 348 in order to enclose the cushion structure 310. Theupper boundary edges 328, 330 of the body panel sections are wrappedaround and seamed to the perimeter of the center panel 320. Accordingly,the upper boundary edge 328 of the first body panel section 322 is of alength sufficient to span the upper boundary edge 352 of the centerpanel as well as one half of each lateral edge thereof. In like fashion,the upper boundary edge 330 of the second body panel section is ofsufficient length to wrap around the remaining perimeter of the centerpanel 320.

The introduction of a seam along the intermediate boundary edges of bothbody panels has been found to have the effect of forcing a portion ofthe body of the airbag to remain substantially at the face of thestructure during a collision event as illustrated in FIG. 6D by thelaterally disposed triangular segments 360, 362 which are substantiallybisected by the seam lines 364, 366 formed along the intermediateboundary edges.

While the prior discussion has largely emphasized the formation ofcushions according to the present invention by cutting the individualfabric panels 20, 22, 24 from sheets of the desired material andthereafter seaming those blanks together in the manner described, thepresent invention also contemplates so called “on-loom” cushionformation. Such formation preferably involves the use of a jacquard ordobby loom as are well known to those of skill in the art. As will beappreciated, these looms permit the formation and attachment of multiplelayers of fabric in a single operation. In addition, these machines canbe programmed to adjust the weave density or cover factor of differentsections of the fabric. Hence it is contemplated that the cushionaccording to the present invention may be either partially or completelyformed on such weaving machines thereby substantially reducing oreliminating subsequent sewing operations.

As will be in each of the illustrated and patentability preferredembodiments, a mouth to remain in the region below the terminus of thelateral boundary edges. As is well known, such mouth openings are matedto the inflator 12 either with or without an additional reinforcementlayer.

In additional to the symmetrical straight-line double peaked mouthforming openings illustrated in FIGS. 3A-B, 5A-B and 6A-B and thearcuate top mount mouth opening illustrated in FIG. 4B, it iscontemplated that multiple different mouth configurations may be appliedto the present invention. By way of example only, and not limitation inFIG. 7A there is illustrated a body panel section 422 similar topreviously described body panel sections 22, 24 but having anonsymmetrical double peaked mouth configuration including a first peak462, and a second peak 464. As will be understood, in the event thatbody panel sections which have such configuration are utilized, theinflator 12 is housed between such peaks either with or withoutadditional mouth reinforcements.

Another potentially preferred mouth configuration is illustrated in FIG.7B wherein there is illustrated a body panel section 522 similar to bodypanel sections 22, 24 but including a mouth-forming configuration of twoangled tab portions 566, 568 on each panel section. These tab portionsmay be disposed around the inflator which is housed in the depressionformed therebetween following cushion formation as described above.

In FIG. 7C there is illustrated yet another mouth forming configurationwherein each body panel section 622 terminates at its lower portion witha box tab 672 as shown. As will be understood, such box tabs may be usedto surround the inflator in a simple and efficient manner.

In FIG. 8, there is illustrated a potentially preferred seamingarrangement for use in establishing the connective relationship betweenthe frontal impact center panel 20 and the body panel sections 22, 24.Each of the sections 22, 24, is made up of panels or pieces 22A, 22B,24A, 24B. As illustrated, the body panel sections 22, 24 are connectedto one another by means of substantially straight body seams 26. Bodypanels 22A, 22B, and 24A, 24B are joined to one another by substantiallystraight body panel seams 25. While only one such body seam 26 and bodypanel seam 25 are illustrated in FIG. 8, it is to be understood that inthe preferred embodiment identical seams are likewise disposed along thelength of the body panel sections 22, 24 and body panels 22B, 24B on theopposite side of the restraint cushion 10. In the illustrated andpotentially preferred embodiment as shown in FIG. 8, the frontal impactpanel 20 is preferably joined to the non-seamed edges of the body panelsections 22, 24 by means of a series of substantially straight faceseams 27 as shown. Once the seaming operations are completed, theinflatable restraint cushion 10 is preferably turned inside out so as toplace the seams on the interior thereof during an inflation event.Moreover, while the assembly configuration as shown in FIG. 8 has arelatively straight line box-like configuration, once the cushion 10 isturned inside out and inflated, the profile tends to assume thegenerally desirable rounded profile as illustrated in FIG. 1.

Although each of the body panel sections 22, 24 are shown as beingcomprised of two panels or pieces 22A, 22B and 24A, 24B, respectively,it is contemplated that each section may be made up of one or morepieces. It is preferred that the pieces be joined by straight seams.

In FIGS. 9A-9C there is illustrated a first potentially preferredconfiguration for the body panel sections 22, 24 (panels or pieces 22A,22B, 24A, 24B) and the frontal impact center panel or section 20 of theinflatable restraint cushion 10 according to the present invention. Asillustrated, each of the body panel sections 22, 24 is generally of adiamond shape including a substantially straight upper boundary edge 28,30 bounded by a first terminal end “A” and a second terminal end “B”.Each of the body panel sections 22, 24 also preferably includes a firstsubstantially straight lateral boundary edge 34, 38 and a secondsubstantially straight lateral boundary edge 36, 40. Each of the bodypanel sections 22, 24 also preferably includes a first substantiallystraight intermediate boundary edge 42, 44 extending between the firstterminal end of the upper boundary edge 28, 30 and the first lateralboundary edge 34, 38 as shown. A second substantially straightintermediate boundary edge 46, 48 preferably connects the secondterminal end of the upper boundary edge 28, 30 of each body panelsection to the second lateral boundary edge 36, 40 thereof.

As illustrated in FIG. 9C the frontal impact center panel 20 ispreferably of a rectilinear geometry including four substantiallystraight boundary edges 52, 54, 56, 58 as shown. The impact center panel20 is preferably of a square or rectangular geometry havingsubstantially right angles between intersecting boundary edges. It iscontemplated that a non-square elongate geometry having a lengthdimension which is substantially greater than the width dimension may beutilized. In such a geometry the length dimension would preferably be atleast ten percent greater that the width dimension, would morepreferably be at least 20 percent greater than the width dimension, andwould most preferably be at least 30 percent greater than the widthdimension, although it is to be understood that such length dimensionmay be substantially greater than these identifiable minimums and may,in fact be many times the width dimension if a substantial area is to becovered.

The materials of construction from which the frontal impact center panel20 and each body panel section 22, 24 of FIGS. 9A-9C are formed, may beeither similar or dissimilar from one another. Each of these panels maybe formed from a number of materials including by way of example onlyand not limitation woven fabrics, knitted fabrics, non-woven fabrics,films and combinations thereof. Woven fabrics may be preferred withwoven fabrics formed of tightly woven construction such as plain orpanama weave constructions being particularly preferred. Such wovenfabrics may be formed from yarns of polyester, polyamides such as nylon6 and nylon-6,6 or other suitable material as may be known to those inthe skill in the art. Multifilament yarns having a relatively low denierper filament rating of not greater than about 1-4 denier per filamentmay be desirable for bags requiring particular good foldability.

In instances where the cushion is to be formed by sewing together precutpanel sections 20, 22, 24 from a base material and a woven fabric isutilized for a frontal impact center panel 20 such panel is preferablycut from the fabric such that its boundary edges are disposedsubstantially parallel to the warp and fill directions. Likewise, ininstances where woven fabric is utilized to form the body panel sections22, 24 such panels are preferably cut such that the upper boundary edges28, 30 run substantially parallel to either the warp or the filldirections.

In application, woven fabrics formed from synthetic yarns having lineardensities of about 40 denier to about 1200 denier are believed to beuseful in the formation of the cushion 10 according to the presentinvention. Fabrics formed from yarns having linear densities of about315 denier to about 840 denier are believed to be particularly useful,and fabrics formed from yarns having linear densities in the range ofabout 400 denier to about 650 denier are believed to be most useful.

While each of the panels 20, 22, 24 may be formed of the same material,the panels may also be formed from differing materials and orconstructions. By way of example only and not limitation, one or both ofthe body panel sections 22, 24 may be formed from an uncoated relativelyhigh permeability fabric having an air permeability of about 5 CFM persquare foot or higher while the center panel 20 is formed from a coatedor uncoated fabric having an air permeability of about 3 CFM per squarefoot or less when measured at a differential pressure of 0.5 inches ofwater across the fabric. Fabrics having permeabilities of about 1-3 CFMper square foot may be desirable in either the body panels or centerpanel section. Fabrics having permeabilities below 2 CFM and preferablybelow 1 CFM in the uncoated state may be preferred. Such fabrics whichhave permeabilities below 2 CFM which permeability does notsubstantially increase by more than a factor of about 2 when the fabricis subjected to biaxial stresses in the range of up to about 100 poundsforce may be particularly preferred. Fabrics which exhibit suchcharacteristics which are formed by means of fluid jet weaving may bemost preferred.

In the event that a coating is utilized on one or more material panels,neoprene, silicone, urethanes, or disperse polymers such as polyamidesmay be preferred. Coatings such as disperse polyamides having dry add onweights of about 0.6 ounces per square yard or less and more preferablyabout 0.4 ounces per square yard or less and most preferably about 0.3ounces per square yard or less may be particularly preferred so as tominimize fabric weight and enhance foldability. It is, of course, to beunderstood that aside from the use of coatings, differentcharacteristics in various panels may also be achieved through the useof fabrics incorporating differing weave densities and/or finishingtreatments such as calendaring as may be known to those in the skill ofthe art.

While the restraint cushion 10 according to the present invention hasbeen illustrated and is described herein in terms of the principal panelsections 20, 22, 24, it is to be understood that such cushion 10 mayalso include additional components such as shape defining tethers, gasvents, mouth reinforcements, and the like as may be known to those inthe skill of the art.

The assembly and construction of the cushion 10 according to the presentinvention is best understood through reference to FIG. 8 and FIGS.9A-9C. In the preferred practice of the present invention, substantiallystraight body panel seams 25 are applied along the abutting edges ofpanels 22A, 22B, and then 24A, 24B. Body seams 26 are applied alongcorresponding lateral boundary edges 34, 38 and 36, 40. The frontalimpact center panel 20 is seamed along two opposing boundary edges 52,54 to the substantially straight upper boundary edges 28, 30 of the bodypanel sections 22, 24. The intermediate boundary edges 42, 44, 46, 48are seamed along the remaining boundary edges 56, 58 of the center panel20 so as to form an enclosed structure. In the illustrated andpotentially preferred embodiment, the total perimeter length of thecenter panel 20 is substantially equal to the combined lengths of theupper boundary edges 28, 30 and intermediate boundary edges 42, 44, 46,48 of the body panel sections. The use of such corresponding lengthsegments permits complete closure using substantially straight seamswithout the occurrence of substantial puckering which may result fromexcess material. In the most preferred embodiment, the upper and lowerboundary edges 52, 54 of the center panel will be of substantially equallength to the upper boundary edges 28, 30 of the body panel sectionswhile the first substantially straight intermediate boundary edges 42,44 of the body panel sections have a combined length which issubstantially equal to the length of the first lateral boundary edge 56of the center panel with the combined lengths of the secondsubstantially straight intermediate boundary edges 46, 48 of the bodypanel sections being substantially equivalent to the length of thesecond center panel lateral boundary edge 58.

As will be appreciated, the preferred geometry permits formation of anenclosed cushion by means of a series of flat, straight seamingoperations to form the body panel seams 25, body seams 26 and face seams27 as illustrated in FIG. 8. Such flat, straight seaming operationsgreatly enhance the efficiency of the manufacturing process. Inaddition, in the event that a woven fabric is chosen as the material ofconstruction, each of the face seams 27 will fall along the primary yarndirections in the center panel 20 thereby lending added stability to thefrontal impact area of the cushion.

In FIGS. 10A-10C there is illustrated a frontal impact center panel orsection 120 and corresponding body panel sections 122, 124, made up ofpanels or pieces 122A, 122B, 124A, 124B, for use in formation of acushion which has a deep arcuate expanded profile such as may bedesirable for surrounding a dash panel in a top mount configuration.That is, where the cushion is deployed from the top of the dash panelrather than from a position directly opposing the occupant. As will beappreciated, the construction and assembly of the restraint cushionincorporating the panel sections as illustrated in FIGS. 10A-C issubstantially identical to the description provided above in relation toFIGS. 9A-C. However, as illustrated the mouth-forming opening isarranged so as to accommodate an inflator in a top mount configuration.Panel sections 120, 122, and 124 have boundary edges 152, 154, 156, 158;128, 134, 136, 142, 146; and, 130, 138, 140, 144, 148, respectively.

In FIGS. 11A-11C there is illustrated a frontal impact center panel orsection 220 and corresponding body panel sections 222, 224, made up ofpanels or pieces 222A, 222B, 224A, 224B, useful in applicationsrequiring a cushion having an elongated profile. By way of example andnot limitation, such application may include full frontal impactprotection or side impact protection for an occupant's head and torso.As illustrated, in this embodiment the body panel sections 222, 224 arecharacterized by upper boundary edges 228, 230 of substantial length anda center panel 220 has corresponding substantial length dimension alongits upper and lower boundary edges 252, 254. As will be noted, thislength dimension is more than two times the width as measured along thelateral boundary edges 256, 258. Once again, the construction issubstantially similar to that described in relation to the priorconfigurations such that the panels 222A, 222B, and 224A, 224B arejoined together, then corresponding first lateral boundary edges 234,238 are joined together; corresponding second lateral boundary edges236, 240 are joined together; upper and lower center panel boundaryedges 252, 254 are joined to the upper boundary edges 228, 230 of thebody panel sections; first intermediate boundary edges 242, 244 of thebody panel sections are joined along a first lateral boundary edge 256of the center panel and second intermediate boundary edges 246, 248 ofthe body panel sections are joined along the remaining lateral boundaryedge 258 of the center panel 220.

As will be appreciated, the resultant elongated cushion structure may bedivided into individual lobes or chambers through the application ofinflation limiting seams or tethers. As will be appreciated theincorporation of such lobes may be desirable to protect differentsections of the body which behave in differing manners during an impactevent. By way of example only and not limitation, an upper lobe may beused to protect the head and torso while a lower lobe may be used toprotect the knee. One potentially preferred seaming configuration todevelop such lobes is disclosed in my pending application Ser. No.08/969,823 the contents of which are incorporated herein by reference.

In FIGS. 12A-12D there is illustrated yet another embodiment of thepresent invention which includes a rectilinear center panel or section320 and two body panel sections 322, 324, made up of panels or pieces322A, 322B, 324A, 324B. As illustrated, the body panel sections of thisembodiment are characterized by a relatively long, substantiallystraight upper boundary edge 328, 330 and intermediate boundary edges342, 344, 346, 348 which are disposed at substantially right angles tosuch upper boundary edges.

The cushion assembly of this embodiment differs slightly from that ofprevious embodiments in that the panels 322A, 322B and 324A, 324B areseamed together along their abutting edges, then the body panel sections322, 324 are seamed together along the corresponding lateral boundaryedges 334, 338 and 336, 340 as well as along corresponding intermediateboundary edges 342, 344 and 346, 348 in order to enclose the cushionstructure 310. The upper boundary edges 328, 330 of the body panelsections are wrapped around and seamed to the perimeter of the centerpanel 320. Accordingly, the upper boundary edge 328 of the first bodypanel section 322 is of a length sufficient to span the upper boundaryedge 352 of the center panel as well as one half of each lateral edgethereof. In like fashion, the upper boundary edge 330 of the second bodypanel section is of sufficient length to wrap around the remainingperimeter of the center panel 320.

The introduction of a seam along the intermediate boundary edges of bothbody panels has been found to have the effect of forcing a portion ofthe body of the airbag to remain substantially at the face of thestructure during a collision event as illustrated in FIG. 12D by thelaterally disposed triangular segments 360, 362 which are substantiallybisected by the seam lines 364, 366 formed along the intermediateboundary edges.

As will be understood, in each of the illustrated and patentabilitypreferred embodiments, a mouth opening is permitted to remain in theregion below the terminus of the lateral boundary edges. As is wellknown, such mouth openings are mated to the inflator 12 either with orwithout additional reinforcement layers.

In addition to the symmetrical straight-line double peaked mouth formingopenings illustrated in FIGS 9A-9B, 11A-11B and 12A-12B and the arcuatetop mount mouth opening illustrated in FIG. 10B, it is contemplated thatmultiple different mouth configurations may be applied to the presentinvention. By way of example only, and not limitation in FIG. 13A thereis illustrated a body panel section 422 (made up of panels or pieces422A, 422B) similar to previously described body panel sections 22, 24but having a nonsymmetrical double peaked mouth configuration includinga first peak 462, and a second peak 464. As will be understood, in theevent that body panel sections which have such configuration areutilized, the inflator 12 is housed between such peaks either with orwithout additional mouth reinforcements.

Another potentially preferred mouth configuration is illustrated in FIG.13B wherein there is illustrated a body panel section 522 (made up ofpanels or pieces 522A, 522B) similar to body panel sections 22, 24 butincluding a mouth-forming configuration of two angled tab portions 566,568 on each panel section. These tab portions may be disposed around theinflator which is housed in the depression formed therebetween followingcushion formation as described above.

In FIG. 13C there is illustrated yet another mouth forming configurationwherein each body panel section 622 (made up of panels or pieces 622A,622B) terminates at its lower portion with a box tab 672 as shown. Aswill be understood, such box tabs may be used to surround the inflatorin a simple and efficient manner.

Although each of the body panel sections are shown as being comprised ofone or two panels or pieces, it is contemplated that each section may bemade up of one or more pieces. It is preferred that the pieces be joinedby straight seams.

In FIGS. 14A-14C there is illustrated another configuration with top,center (body), and bottom panel sections 702, 704, 706 and the top panelsection serves as the frontal impact panel or section of the inflatablerestraint cushion according to the present invention.

The airbag of the embodiment shown in FIGS. 14A-14C of the drawings ismanufactured by attaching the panel sections 702, 704, and 706 to oneanother by the following steps:

1. Align any reinforcement patches around the mouth and vents using, forexample, pre-cut alignment holes and sew the seams to secure thereinforcements.

2. Connect (3, 5) to (3′, 5′).

3. Connect (4, 6) to (4′, 6′).

4. Connect (5, 7, 8, 6) to (5″, 7″, 8″, and 6″).

In FIGS. 15A-15C there is illustrated still another configuration withtop, center (body), and bottom panel sections 802, 804, and 806 with thetop panel section serving as the frontal impact panel of the inflatablerestrain cushion according to the present invention.

The panel sections shown in FIGS. 15A-15C of the drawings aremanufactured or attached to one another to form an airbag cushion by thefollowing steps:

1. Align any reinforcement patches around the mouth and vents using, forexample, pre-cut alignment holes and sew the seams to secure thereinforcements.

2. Connect (3, 5) to (3′, 5′).

3. Connect (4, 6) to (4′, 6′).

4. Connect (5, 7, 8, 6) to (5″, 7″, 8″, and 6″).

With reference to FIGS. 16A-16C of the drawings, each of the panelsections 702, 704, and 706 is formed of a plurality of section panels,respectively, 702A, 702B, 704A, 704B, and 706A, 706B. Although each ofthe panel sections is shown to be formed of two panels or pieces, it isto be understood that they may be formed of two or more panels.

In the manufacture of an airbag from the section panels shown in FIGS.16A-16C, it is preferred to join the section panels prior to joining thepanel sections. The section panels are joined by seams along theadjacent or abutting edges of the section panels.

With reference to FIGS. 17A-17C of the drawings, each of the top,center, and bottom panel sections 802, 804, and 806 is shown to beformed from a plurality of section panels, respectively, 802A, 802B,804A-804F, and 806A, 806B. Like the panels shown in FIGS. 16A-16C, thepanels shown in FIGS. 17A-17C are preferably joined to one another priorto the joining, connection or attachment of the panel sections.

In FIGS. 18A-18D of the drawings, there is illustrated still anotherconfiguration with a top panel section 902, a center or body panelsection 904, and loop pocket or inflator attachment panel sections 906and 908. The panel sections 902, 904, 906, and 908 are attached to oneanother and an airbag is formed by the following steps;

1. Align any reinforcement patches and vents using, for example, pre-cutalignment holes and sewing the seams to secure the reinforcements.

2. Connect or attach (3, 5) to (3′, 5′).

3. Attach (1′, 2′) to (1″, 2″).

4. Attach (4) to (4″) and (6) to (6″) to complete the conical structure.

5. Attach the front panel by sewing (7,8) to (7′″, 8′″) and (4,6) to(4′″, 6′″).

With reference to FIGS. 19A-19D of the drawings, each of the panelsections 902, 904, 906, and 908 are shown to be formed of a plurality ofsection panels, respectively, 902A, 902B, 904A-904D, 906A, 906B, and908A, 908B. In the manufacture of an airbag from these panels, it ispreferred that the section panels be joined to one another along theabutting or adjacent edges prior to the joining, attachment, orconnection of the panel sections.

With reference to FIGS. 20-25 of the drawings and in accordance with yetother embodiments of the present invention, preferably a unitary,elongated, notched body panel 1000 is adapted to be used with asubstantially rectangular (or square) center or front panel. The bodypanel 1000 of FIG. 20 is a single body panel in place of separate bodypanel sections (top and bottom sections) as shown, for example, in FIGS.3A, 3B, 5A, 5B, 6A, 6B, 7A, 7B, 7C, 9A, 9B, etc. If desired the bodypanel 1000 may be made in sections and connected together in anysuitable fashion to form the body panel 1000.

The body panel 1000 includes equal sized right and left notches 1002,1003, and an inflator opening 1004. The notches 1002, 1003, may be sizedlarger to provide more profile to the bag (FIG. 23) as shown by thedashed line notches 1006, 1007 in FIG. 20. Preferably the apex of thenotches 1002 and 1003 are located on the centerline of the inflatoropening 1004.

In FIGS. 21 and 22 there is illustrated a potentially preferredconfiguration for the body panel 1010 and the frontal impact centerpanel 1020 of an inflatable restraint cushion 1030 according to thepresent invention.

The assembly and construction of the cushion 1030 according to thepresent invention is best understood through reference to FIG. 23 andFIGS. 21 and 22. In the preferred practice of the present invention, thenotches are sewn shut by connecting 5-6-5′ and 7-8-7′, each by astraight seam line, then the front panel 1020 is connected to the bodypanel 1010 by connecting (1, 2, 3, 4) to (1′, 2′, 3′, 4′). The straightseams prevent the cushion 1030 from expanding uncontrolled to cause thefront panel 1020 to impact the driver or occupant of the vehicle inwhich it is installed. The straight seams negate the use of a tether tocontrol expansion of the cushion and reduces the elongation over thetypical air bag by about 30%.

Body panel 1040 and front panel 1050 of FIGS. 24 and 25, respectivelyare like body panel 1000 of FIG. 20 or body panel 1010 of FIG. 21 andfront panel 1020 of FIG. 22 and are joined to form an airbag in asimilar fashion.

The body panels, front panels, and airbags of FIGS. 20-25 of thedrawings are especially adapted to form passenger side airbags and canbe formed, for example, to provide for top of 3/4 mount airbags.

While specific embodiments of the invention have been illustrated anddescribed, it is to be understood that the invention is not limitedthereto, since modifications may certainly be made and other embodimentsof the principals of this invention will no doubt occur to those skilledin the art. Therefore, it is contemplated by the appended claims tocover any such modifications and other embodiments as incorporate thefeatures of this invention which in the true spirit and scope of theclaims hereto.

What is claimed is:
 1. An airbag cushion for use in a vehicle restraint system, the cushion comprising: a notched body panel having notches in boundary edges thereof; and a substantially rectangular frontal center panel; said notches of said body panel being seamed together along abutting edges thereof to fold said body panel and form a profile, said body panel and said center panel being seamed together along corresponding boundary edges of said body panel and around the entire perimeter of said center panel by a series of substantially straight seams thereby forming an inflatable structure.
 2. The cushion as recited in claim 1, wherein said rectangular center panel is substantially square.
 3. The cushion as in claim 1, wherein said rectangular center panel is of an elongated rectangular geometry wherein said geometry has a length dimension greater than its width dimension.
 4. The cushion as recited in claim 3, wherein said length dimension is at least 30 percent greater than said width dimension.
 5. The cushion as recited in claim 4, wherein said length dimension is at least twice as great as said width dimension.
 6. The cushion as recited in claim 1, wherein said body panel and said center panel each comprise a woven fabric.
 7. The cushion as recited in claim 6, wherein the woven fabric which comprises said body panel exhibits permeability characteristics which differ from the fabric which comprises said center panel.
 8. The cushion as recited in claim 6, wherein the woven fabric which comprises said body panel is an uncoated fabric and the woven fabric which comprises said center panel is a coated fabric.
 9. The cushion as recited in claim 8, wherein said coated fabric is coated with a disperse polymer having a dry add on weight of not greater than about 0.4 ounces per square yard.
 10. The cushion as recited in claim 6, wherein the fabric which comprises at least one of said body panel and said center panel is woven from a plurality of multifilament synthetic yarns wherein the filaments forming said synthetic yarns are characterized by a linear density of about 4 denier per filament or less.
 11. The cushion as recited in claim 10, wherein said multifilament synthetic yarns are characterized by a yarn linear density of about 840 denier or less.
 12. The cushion as recited in claim 6, wherein the woven fabric which comprises said body panel is uncoated, and the woven fabric which comprises said center panel is uncoated.
 13. The cushion as recited in claim 6, wherein the woven fabric which comprises said center panel is characterized by an air permeability of about 1-3 cubic feet per minute per square foot of fabric at a differential pressure of 0.5 inches of water.
 14. The cushion as recited in claim 1, wherein said notched body panel includes first and second notches that are V-shaped.
 15. The cushion as recited in claim 14, wherein each of said first and second notches have an apex angle of not greater than about 90 degrees.
 16. The cushion as recited in claim 1, wherein said body panel is made up of a plurality of panel sections.
 17. In a vehicle restraint system, the improvement comprising the cushion of claim
 1. 18. In an airbag module, the improvement comprising the cushion of claim
 1. 19. The cushion of claim 1 in which the body panel is longer than it is wide and the notches are in the sides of said body panel.
 20. The cushion of claim 1 wherein an inflator opening is located in said body panel between said notches.
 21. The cushion of claim 20 wherein said notches are of substantially equal size.
 22. The cushion of claim 21 wherein the apex of each notch is located substantially along a center line of said inflator opening.
 23. An airbag cushion for use in a vehicle restraint system, the cushion comprising: a notched body panel having notches in boundary edges thereof; and a rectangular frontal center panel; said notches of said body panel being seamed together along abutting edges thereof to fold said body panel and form a profile, and said body panel and said center panel being seamed together along corresponding boundary edges of said body panel and around the entire perimeter of said center panel by a series of substantially straight seams thereby forming an inflatable structure whereby said seamed notches prevent said body panel from uncontrollable expanse.
 24. The cushion as recited in claim 23, wherein said rectangular center panel is substantially square.
 25. The cushion as in claim 23, wherein said rectangular center panel is of an elongated rectangular geometry wherein said geometry has a length dimension greater than its width dimension.
 26. The cushion as recited in claim 25, wherein said length dimension is at least 30 percent greater than said width dimension.
 27. The cushion as recited in claim 26, wherein said length dimension is at least twice as great as said width dimension.
 28. An airbag cushion for use in a vehicle restraint system for protecting an occupant of a vehicle, the cushion comprising: a notched body panel having notches in the sides thereof and an inflator opening; a rectangular frontal center panel; said notches of said body panel being seamed together along abutting edges thereof to fold said body panel and form a profile, and said body panel and said cener panel being seamed together along corresponding boundary edges of said body panel and around the entire perimeter of said center panel by a series of substantially straight seams thereby forming an inflatable structure wherein said seamed notches prevent the body panel from excessive expansion to prevent said center panel from hitting an occupant of a vehicle with excessive force upon inflation of the airbag cushion.
 29. The cushion as recited in claim 28, wherein said rectangular center panel is substantially square.
 30. The cushion as in claim 28, wherein said rectangular center panel is of an elongated rectangular geometry wherein said geometry has a length dimension greater than its width dimension.
 31. The cushion as recited in claim 30, wherein said length dimension is at least 30 percent greater than said width dimension.
 32. The cushion as recited in claim 31, wherein said length dimension is at least twice as great as said width dimension. 